Ladder, wide rung and method

ABSTRACT

A ladder having a first rail and a second rail. The ladder having a standard rung having a width permanently attached to the first rail and the second rail. The ladder having a first wide rung having a width greater than the width of the standard rung, which is permanently attached to the first rail and the second rail. The ladder having a second wide rung having a width greater than the width of the standard rung, which is permanently attached to the first rail and the second rail. The first wide rung and the second wide rung are disposed in a work zone of the ladder. The work zone of the ladder is where a user typically stands on the ladder while performing tasks. The standard rung is disposed outside the work zone. A wide rung. A method for using a ladder. A method for producing a ladder.

FIELD OF THE INVENTION

The present invention is related to a ladder having wide rungs locatedin a work zone of the ladder. (As used herein, references to the“present invention” or “invention” relate to exemplary embodiments andnot necessarily to every embodiment encompassed by the appended claims.)More specifically, the present invention is related to a ladder havingwide rungs located in a work zone of the ladder where the wide rungs areattached with fasteners through covers to the rails of the ladder.

BACKGROUND OF THE INVENTION

This section is intended to introduce the reader to various aspects ofthe art that may be related to various aspects of the present invention.The following discussion is intended to provide information tofacilitate a better understanding of the present invention. Accordingly,it should be understood that statements in the following discussion areto be read in this light, and not as admissions of prior art.

When using a ladder, the wider the rung that the user stands on,typically the more secure the user feels standing on the rung becausethe wider the rung the wider the surface area for the user to place hisor her feet on the rung. By having a greater surface area, it feels morelike standing on the ground or a floor that is the natural position foruser when standing.

The width of a rung is determined by the amount of material used for thewrong, how the rung is attached to a rail, and that the rung does notinterfere with the operation or the use of the ladder. The amount ofmaterial is desired to be minimized to reduce the weight that the rungcontributes to the overall weight of the ladder, yet still be strongenough to support the necessary weight of the user. The rung needs to besecurely attached to the rails of the ladder so there is no issue thatwhen the user stands on the rung, the rung will not come loose a breakaway from the rails. The rung cannot be so wide that it interferes withthe user climbing the rungs and possibly catching a foot on the rung isa user climbs a ladder, or striking a knee against the rung as the userlifts his or her leg there's the user climbs the ladder. In addition,the rung should not be so wide that it could catch on an object when theladder is being moved, where make it difficult for the ladder to bestored. Furthermore, in regard to an extension ladder, the rungs shouldnot interfere with the movement of the sections of the extension ladder.In regard to a stepladder, the rungs should not impede with the openingand closing of the sections. Accordingly, it is generally desired toprovide for a rung with a width as large as possible given theaforementioned constraints.

BRIEF SUMMARY OF THE INVENTION

The present invention pertains to a ladder. The ladder comprises a firstrail. The ladder comprises a second rail. The ladder comprises astandard rung having a width permanently attached to the first rail andthe second rail. The ladder comprises a first wide rung having a widthgreater than the width of the standard rung, which is permanentlyattached to the first rail and the second rail. The ladder comprises asecond wide rung having a width greater than the width of the standardrung, which is permanently attached to the first rail and the secondrail. The first wide rung and the second wide rung are disposed in awork zone of the ladder. The work zone of the ladder is where a usertypically stands on the ladder while performing tasks. The standard rungis disposed below the work zone.

The present invention pertains to a wide rung for attachment to a firstrail and a second rail of a ladder. The wide rung comprises a topportion and a front and a back and a right side and a left side. Thewide rung comprises first segment connected to and extending down fromthe front of the top portion, a second segment connected to andextending down from the back of the top portion, a third segmentconnected to and extending inward toward the back from the firstsegment, a fourth segment connected to and extending down from thesecond segment inward toward the front and connected to the thirdsegment two. The wide rung comprises a first boss adjacent the front ofthe top portion, a second boss adjacent the back of the top portion, anda third boss adjacent to the third and fourth segments. The wide rung ishollow and a one piece extrusion and having a somewhat D-shapedcross-section.

The present invention pertains to a method for climbing a ladder. Themethod comprises the steps of placing a foot by a user on a standardrung attached to a first rail and a second rail of the ladder, thestandard rung having a width. There is the step of placing the foot ofthe user on a first wide rang attached to the first rail and the secondrail of the ladder. The first wide rung having a width greater than thewidth of the standard rung. The ladder having a second wide rung havinga width greater than the width of the standard rung attached to thefirst rail and the second rail. The first wide rung and the second widerung disposed in a work zone of a ladder. The standard rung disposedoutside the work zone of the ladder. The first wide rung is hollow and aone piece extrusion having a right side and a left side and a somewhatD-shaped cross-section formed of a top portion having a width greaterthan the width of a standard rung, and a front and a back. A firstsegment is connected to and extending down from the front of the topportion. A second segment is connected to and extending down from theback of the top portion. A third segment is connected to and extendinginward toward the back from the first segment. A fourth segment isconnected to and extending down from the second segment inward towardthe front and connected to the third segment. There is a first bossadjacent the front of the top portion, a second boss adjacent the backof the top portion, and a third boss adjacent to the third and fourthsegments. The ladder including a right cover attached to the right sideof the first wide rung, a left cover attached to the left side of thefirst wide rung. Each cover having a cross-section which conforms withthe cross-section of the first wide rung, a closed face having a firsthole and a second hole in a third hole whose locations in the lace alignwith the first boss and second boss and third boss, respectively. Eachcover has a top side that extends inward from the face in alignment withthe top portion and is positioned over the top portion, a first sidethat extends inward from the face in alignment with the first segmentand is positioned over the first segment, a second side that extendsinward from the face in alignment with the second segment and ispositioned over the second segment, a third side that extends inwardfrom the face in alignment with, the third segment and is positionedover the third segment, and a fourth side that extends inward from theface in alignment with the fourth segment and is positioned over thefourth segment. The ladder including right side fasteners which extendthrough the first rail and the first and second and third holes of theright cover and the first and second and third bosses, respectively, toattach the right side of the first wide rung and the right cover to thefirst rail, the ladder including left side fasteners which extendthrough the second rail and the first and second and third holes of theleft cover and the first and second and third bosses, respectively, toattach the left side of the first wide rung and the left cover to thesecond rail.

The present invention pertains to a method for producing a ladder. Themethod comprises the steps of attaching a standard rung having a widthto a first rail and a second rail of a ladder. There is the step ofattaching a first wide rung to the first rail and the second rail of theladder, the first wide rung having a width greater than the width of thestandard rung. There is the step of attaching a second wide rung to thefirst rail and the second rail of the ladder. The second wide runghaving a width greater than the width of the standard rung.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

In the accompanying drawings, the preferred embodiment of the inventionand preferred methods of practicing the invention are illustrated inwhich:

FIG. 1 shows a ladder of the present invention.

FIG. 2 is an exploded view of the ladder.

FIG. 3 is a cross-sectional view of a wide rung.

FIG. 4 is a perspective view of the wide rung.

FIG. 5 is a rear perspective view of a left cover.

FIG. 6 is a front perspective view of the right cover.

FIG. 7 is an overhead view of a cover.

FIG. 8 is a side view of the cover.

FIG. 9 is a back view of the cover.

FIG. 10 is a side view of the cover.

FIG. 11 is an exploded view of the ladder using rung plates.

DETAILED DESCRIPTION OF THE INVENTION

Referring now to the drawings wherein like reference numerals refer tosimilar or identical parts throughout the several views, and morespecifically to FIGS. 1 and 2 thereof, there is shown a ladder 10. Theladder 10 comprises a first rail 12. The ladder 10 comprises a secondrail 14. The ladder 10 comprises a standard rung 16 having a widthpermanently attached to the first rail 12 and the second rail 14. Theladder 10 comprises a first wide rung 18 having a width greater than thewidth of the standard rung 16, which is permanently attached to thefirst rail 12 and the second rail 14. The ladder 10 comprises a secondwide rung 20 having a width greater than the width of the standard rung16, which is permanently attached to the first rail 12 and the secondrail 14. The first wide rung 18 and the second wide rung 20 are disposedin a work zone 72 of the ladder 10. The work zone 72 of the ladder 10 iswhere a user typically stands on the ladder 10 while performing tasks.The standard rung 16 is disposed below the work zone 72.

The first wide rung 18 may be hollow and include a one piece extrusionhaving a right side 22 and a left side 24 and a somewhat D-shapedcross-section, as shown in FIGS. 3 and 4. The first wide rung 18 may beformed of a top portion 26 having a width wider than the width of thefirst rail 12 find a front 28 and a back 30, a first segment 32connected to and extending down from the front 28 of the top portion 26,a second segment 34 connected to and extending down from the back 30 ofthe top portion 26, a third segment 36 connected to and extending inwardtoward the back 30 from the first segment 32, a fourth segment 38connected to and extending down from the second segment 34 inward towardthe front 28 and connected to the third segment 36. The first wide rung18 may include a first boss 40 adjacent the front 28 of the top portion26, a second boss 42 adjacent the back 30 of the top portion 26, and athird boss 44 adjacent to the third and fourth segments 36, 38.

As shown in FIGS. 5-10, the first wide rung 18 may include a right cover46 attached to the right side 22 of the first wide rung 18. The firstwide rung 18 may include a left cover 48 attached to the left side 24 ofthe first wide rung 18. Each cover may have a cross-section whichconforms with the cross-section of the first wide rung 18, a closed face50 having a first hole 52 and a second hole 54 in a third hole 56 whoselocations in the face 50 align with the first boss 40 and second boss 42and third boss 44, respectively. Each cover may include steps a top side66 that extends inward from the face 50 in alignment with the topportion 26 and is positioned over the top portion 26, a first side 58that extends inward from the face 50 in alignment with the first segment32 and is positioned over the first segment 32, a second side 60 thatextends inward from the lace 50 in alignment with the second segment 34and is positioned over the second segment 34, a third side 62 thatextends inward from the face 50 in alignment with the third segment 36and is positioned over the third segment 36, and a fourth side 64 thatextends inward from the face 50 in alignment with the fourth segment 38and is positioned over the fourth segment 38.

The first wide rung 18 may include right side fasteners 68 which extendthrough the first rail 12 and the first and second and third holes 52,54, 56 of the right cover 46 and the first and second and third bosses40, 42, 44, respectively, to attach the right side 22 of the first widerung 18 find the right cover 46 to the first rail 12, as shown in FIG.2. The first wide rung 18 may include left side fasteners 70 whichextend through the second rail 14 and the first and second and thirdholes 52, 54, 56 of the left cover 48 and the first, and second andthird bosses 40, 42, 44, respectively, to attach the left side 24 of thefirst wide rung 18 and the left cover 48 to the second rail 14. Therails have predrilled holes aligned with the holes in the covers and thethree bosses to facilitate the placement of the fasteners.

The first and second wide rungs 18, 20 may be the only wide rungsattached to the first and second rails 12, 14, although there may be athird or a fourth or even more wide rungs attached to the first andsecond rails 12, 14 in the work zone 72, as needed indicated by the use.Each cover may be made of plastic and each wide rung may be made ofaluminum. As shown in FIGS. 5 and 9, each cover may have a first plate74 extending inward from the face 50 and in parallel and spaced relationfrom the top side 66 to define a first slot 80 in which the lop portion26 is disposed, a second plate 76 extending inward from the face 50 andin parallel space relation from the third side 62 to define a secondslot 82 in which the third segment 36 is disposed, and a third plate 78extending inward from the face 50 and in parallel and spaced relationfrom the fourth side 64 to define a third slot 84 in which the fourthsegment 38 is disposed.

The present invention pertains to a wide rung for attachment to a firstrail 12 and a second rail 14 of a ladder 10. The wide rung comprises atop portion 26 and a front 28 and a back 30 and a right side 22 and aleft side 24. The wide rung comprises first segment 32 connected to andextending down from the front 28 of the top portion 26, a second segment34 connected to and extending down from the back 30 of the top portion26, a third segment 36 connected to and extending inward toward the back30 from the first segment 32, a fourth segment 38 connected to andextending down from the second segment 34 inward toward the front 28 andconnected to the third segment 36 two. The wide rung comprises a firstboss 40 adjacent the front 28 of the top portion 26, a second boss 42adjacent the back 30 of the top portion 26, and a third boss 44 adjacentto the third and fourth segments 36, 38. The wide rung is hollow and aone piece extrusion and having a somewhat D-shaped cross-section.

The present invention pertains to a method for climbing a ladder 10. Themethod comprises the steps of placing a foot by a user on a standardrung 16 attached to a first rail 12 and a second rail 14 of the ladder10, the standard rung 16 having a width. There is the step of placingthe foot of the user on a first wide rung 18 attached to the first rail12 and the second rail 14 of the ladder 10. The first wide rung 18having a width greater than the width of the standard rung 16. Theladder 10 having a second wide rung 20 having a width greater than thewidth of the standard rung 16 attached to the first rail 12 and thesecond rail 14. The first wide rung 18 and the second wide rung 20disposed in a work zone 72 of a ladder 10. The standard rung 16 disposedoutside the work zone 72 of the ladder 10. The first wide rung 18 ishollow and a one piece extrusion having a right side 22 and a left side24 and a somewhat D-shaped cross-section formed of a top portion 26having a width greater than the width of a standard rung 16, and a front28 and a hack 30. A first segment 32 is connected to and extending downfrom the front 28 of the top portion 26. A second segment 34 isconnected to and extending down from the back 30 of the top portion 26.A third segment 36 is connected to and extending inward toward the back30 from the first segment 32. A fourth segment 38 is connected to andextending down from the second segment 34 inward toward the front 28 andconnected to the third segment 36. There is a first boss 40 adjacent thefront 28 of the top portion 26, a second boss 42 adjacent the back 30 ofthe top portion 26, and a third boss 44 adjacent to the third and fourthsegments 36, 38. The ladder 10 including a right cover 46 attached tothe right side 22 of the first wide rung 18, a left cover 48 attached tothe left side 24 of the first wide rung 18. Each cover having across-section which conforms with the cross-section of the first widerung 18, a closed face 50 having a first hole 52 and a second hole 54 ina third hole 56 whose locations in the face 50 align with the first boss40 and second boss 42 and third boss 44, respectively. Each cover has atop side 66 that extends inward from the face 50 in alignment with thetop portion 26 and is positioned over the top portion 26, a first side58 that extends inward from the face 50 in alignment with the firstsegment 32 and is positioned over the first segment 32, a second side 60that extends inward from the face 50 in alignment with the secondsegment 34 and is positioned over the second segment 34, a third side 62that extends inward from the face 50 in alignment with the third segment36 and is positioned over the third segment 36, and a fourth side 64that extends inward from the face 50 in alignment with the fourthsegment 38 and is positioned over the fourth segment 38. The ladder 10including right side fasteners 68 which extend through the first rail 12and the first and second and third holes 52, 54, 56 of the right cover46 and the first and second and third bosses 40, 42, 44, respectively,to attach the right side 22 of the first wide rung 18 and the rightcover 46 to the first rail 12, the ladder 10 including left sidefasteners 70 which extend through the second rail 14 and the first andsecond and third holes 52, 54, 56 of the left cover 48 and the first andsecond and third bosses 40, 42, 44, respectively, to attach the leftside 24 of the first wide rung 18 and the left cover 48 to the secondrail 14.

The present invention pertains to a method for producing a ladder 10.The method comprises the steps of attaching a standard rung 16 having awidth to a first rail 12 and a second rail 14 of a ladder 50. There isthe step of attaching a first wide rung 18 to the first rail 12 and thesecond rail 14 of the ladder 10, the first wide rung 18 having a widthgreater than the width of the standard rung 16. There is the step ofattaching a second wide rung 20 to the first rail 12 and the second rail14 of the ladder 10. The second wide rung 20 having a width greater thanthe width of the standard rung 16.

This invention consists of extruded aluminum ladder 10 rungsspecifically designed to be used in the “work zone 72” at the upper endof an extension ladder fry section. These rungs are wider from front 28to rear so as to provide a more comfortable standing surface thanconventional round or D-shaped rungs. Because of their wider and flattershape, these rungs are not swaged to the rails in the usual fashion butare designed with integral bosses to receive self-threading screws tohold them solidly to the rails.

The use of wider rungs in the “work zone 72” of climbing products can beapplied to step ladders, MT ladders, M ladders, and attic ladders, etc.The use of wide rungs provides significantly increased comfort forladder users working in the work zone 72 near the top of the ladder 10.As an example, the top portion 26 of each wide rung may be between 2inches and 4 inches and preferably about 2.5 inches wide, and the lengthof each wide rung is between 12 inches and 16 inches and preferablyabout 14.5 inches. The top side 66 of each cover is about 0.1 incheswider than the width of the top portion 26 so the top side 66 can snuglyand tightly fit over the top portion 26. The length of the sides of eachcover is about an inch to two inches. The width of the rails, preferablyabout 3 inches, is slightly larger than the width of the cover so thecover and the wide rung do not extend beyond the width of the rails.

Each cover has a cover channel 86 disposed at the center of the top side66 which aligns with a rung channel 88 disposed about the center of thetop portion 26. The rung channel 88 serves to facilitate the properplacement of a cover with the rung. The cover channel 86 is positionedto fit into the rung channel 88 when each cover is placed onto an end ofthe rung so each cover is in proper position.

FIG. 11 shows the use of a right rung plate 90 and a left rung plate 92to secure and attach the first wide rung 18 to the first rail 12 andsecond rail 14, respectively, as an alternative technique to the use ofthe right cover 46 and the left cover 48. Each rung plate has a centerportion 96 with at least one, and preferably three plate holes 98. Theright rung plate 90 receives right side fasteners 68, preferably screws,in each of the plate holes 98 that engage with first, second and thirdbosses to attach the right rung plate 90 to the first wide rung 18.Similarly, left side fasteners 70, preferably screws, extend through thethree plate holes 98 in the left rung plate 92 into the first, secondand third bosses to attach the left rung plate 92 to the first wide rung18. In turn, the right rung plate 90, now attached to the first widerung 18, is attached to the first rail 12 with rivets 94 that extendsthrough the first rail 12, preferably at a web 100 of the first rail 12and into the upper flange holes 102 of an upper flange 104 of the firstrung plate, and lower flange holes 106 of lower flange 108 of the firstrung plate 92, to secure the first rung plate 90 to the first rail 12.The lower flange 108 is connected to and below the center portion 96 andthe upper flange 104 is connected to and above the center portion 96.The left rung plate 92, now attached to the first wide rung 18, issimilarly attached to the second rail 14 as the right rung plate 90 isattached to the first rail 12. In this way, the right and left rungplates act as intermediary components to attach the first wide rung 18to the first and second rails. Whether covers or rung plates are used toattach the wide rungs to the rails, the wide rungs support at least 250lbs., and preferably at least 400 lbs. without failure.

Although the invention has been described in detail in the foregoingembodiments for the purpose of illustration, it is to be understood thatsuch detail is solely for that purpose and that variations can be madetherein by those skilled in the art without departing from the spiritand scope of the invention except as it may be described by thefollowing claims.

The invention claimed is:
 1. A ladder comprising: a first rail; a secondrail; a first rung having a width and being attached to the first andsecond rails; a second rung which is hollow and being of a one pieceextrusion; the second rung having a right side and a left side and agenerally D-shaped cross-section formed of a top portion having a widthwhich is wider than the width of the first rung, a front and a back, afirst segment connected to and extending down from the front of the topportion, a second segment connected to and extending down from the backof the top portion, a third segment connected to and extending inwardtoward the back from the first segment, a fourth segment connected toand extending down from the second segment inward toward the front andconnected to the third segment, a first boss adjacent the front of thetop portion, a second boss adjacent the back of the top portion, and athird boss adjacent to the third and fourth segments; a right coverattached to the right side of the second rung; a left cover attached tothe left side of the second rung, each cover having a cross-sectionwhich conforms with the cross-section of the first wide rung, a closedface having a first hole and a second hole and a third hole whoselocations in the face align with the first boss and second boss andthird boss, respectively, a top side that extends inward from the facein alignment with the top portion and is positioned over the topportion, a first side that extends inward from the face in alignmentwith the first segment and is positioned over the first segment, asecond side that extends inward from the face in alignment with thesecond segment and is positioned over the second segment, a third sidethat extends inward from the face in alignment with the third segmentand is positioned over the third segment, and a fourth side that extendsinward from the face in alignment with the fourth segment and ispositioned over the fourth segment; right side fasteners which extendthrough the first rail and the first and second and third holes of theright cover and the first and second and third bosses, respectively, toattach the right side of the second rung and the right cover to thefirst rail; left side fasteners which extend through the second rail andthe first and second and third holes of the left cover and the first andsecond and third bosses, respectively, to attach the left side of thesecond rung and the left cover to the second rail; and a third runghaving a width greater than the width of the first rung and attached tothe first and second rails; and wherein the second and third rungs areattached to the first and second rails along one portion of the ladderand the first rung is attached to another portion of the ladder does notinclude the second and third rungs.
 2. The ladder of claim 1 wherein thesecond and third rungs are the only rungs of their respective widthsattached to the first and second rails.
 3. The ladder of claim 2 whereineach cover is made of plastic and each of the second and third rungs aremade of aluminum.
 4. The ladder of claim 3 wherein each cover has afirst plate extending inward from the face and in parallel and spacedrelation from the top side to define a first slot in which the topportion is disposed, a second plate extending inward from the face andin parallel space relation from the third side to define a second slotin which the third segment is disposed, and a third plate extendinginward from the face and in parallel and spaced relation from the fourthside to define a third slot in which the fourth segment is disposed. 5.A ladder comprising: a first rail; a second rail; a first rung having awidth and attached to the first and second rails; a second rung which ishollow and being of a one piece extrusion; the second rung having aright side and a left side and a generally D-shaped cross-section formedof a top portion having a width wider than the width of the first rungand a front and a back, a first segment connected to and extending downfrom the front of the top portion, a second segment connected to andextending down from the back of the top portion, a third segmentconnected to and extending inward toward the back from the firstsegment, a fourth segment connected to and extending down from thesecond segment inward toward the front and connected to the thirdsegment, a first boss adjacent the front of the top portion, a secondboss adjacent the back of the top portion, and a third boss adjacent tothe third and fourth segments; a right rung plate attached to the rightside of the second rung; a left rung plate attached to the left side ofthe second rung, each rung plate having a center portion having a firstcenter hole and a second center hole and a third center hole whoselocations in the center portion align with the first boss and secondboss and third boss, respectively, an upper flange that extends from andabove the center portion, and a lower flange that extends from and belowthe center portion, the upper flange having upper flange holes and thelower flange having lower flange holes, rivets extending through thefirst rail and the second rail into the upper flange holes and the lowerflange holes of each rung plate to attach the right rung plate and theleft rung plate to the first rail and second rail, respectively, andthus the second rung to the first rail and the second rail; and a thirdrung having a width greater than the width of the first rung andattached to the first and second rails, and wherein the second and thirdrungs are attached to the first and second rails along one portion ofthe ladder and the first rung is attached to another portion of theladder does not include the second and third rungs.